AU2010203597A1 - Method and treatment composition for imparting durable antimicrobial properties to carpet - Google Patents

Method and treatment composition for imparting durable antimicrobial properties to carpet Download PDF

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AU2010203597A1
AU2010203597A1 AU2010203597A AU2010203597A AU2010203597A1 AU 2010203597 A1 AU2010203597 A1 AU 2010203597A1 AU 2010203597 A AU2010203597 A AU 2010203597A AU 2010203597 A AU2010203597 A AU 2010203597A AU 2010203597 A1 AU2010203597 A1 AU 2010203597A1
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carpet
treatment composition
foam
antimicrobial compound
composition
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AU2010203597B2 (en
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James Lesslie
Todd Mull
Danny S. Wade
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Beaulieu Group LLC
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Beaulieu Group LLC
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    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M16/00—Biochemical treatment of fibres, threads, yarns, fabrics, or fibrous goods made from such materials, e.g. enzymatic
    • A—HUMAN NECESSITIES
    • A01—AGRICULTURE; FORESTRY; ANIMAL HUSBANDRY; HUNTING; TRAPPING; FISHING
    • A01N—PRESERVATION OF BODIES OF HUMANS OR ANIMALS OR PLANTS OR PARTS THEREOF; BIOCIDES, e.g. AS DISINFECTANTS, AS PESTICIDES OR AS HERBICIDES; PEST REPELLANTS OR ATTRACTANTS; PLANT GROWTH REGULATORS
    • A01N43/00—Biocides, pest repellants or attractants, or plant growth regulators containing heterocyclic compounds
    • A01N43/34—Biocides, pest repellants or attractants, or plant growth regulators containing heterocyclic compounds having rings with one nitrogen atom as the only ring hetero atom
    • A01N43/40—Biocides, pest repellants or attractants, or plant growth regulators containing heterocyclic compounds having rings with one nitrogen atom as the only ring hetero atom six-membered rings
    • A—HUMAN NECESSITIES
    • A01—AGRICULTURE; FORESTRY; ANIMAL HUSBANDRY; HUNTING; TRAPPING; FISHING
    • A01N—PRESERVATION OF BODIES OF HUMANS OR ANIMALS OR PLANTS OR PARTS THEREOF; BIOCIDES, e.g. AS DISINFECTANTS, AS PESTICIDES OR AS HERBICIDES; PEST REPELLANTS OR ATTRACTANTS; PLANT GROWTH REGULATORS
    • A01N25/00—Biocides, pest repellants or attractants, or plant growth regulators, characterised by their forms, or by their non-active ingredients or by their methods of application, e.g. seed treatment or sequential application; Substances for reducing the noxious effect of the active ingredients to organisms other than pests
    • A01N25/08—Biocides, pest repellants or attractants, or plant growth regulators, characterised by their forms, or by their non-active ingredients or by their methods of application, e.g. seed treatment or sequential application; Substances for reducing the noxious effect of the active ingredients to organisms other than pests containing solids as carriers or diluents
    • A01N25/10—Macromolecular compounds
    • A—HUMAN NECESSITIES
    • A01—AGRICULTURE; FORESTRY; ANIMAL HUSBANDRY; HUNTING; TRAPPING; FISHING
    • A01N—PRESERVATION OF BODIES OF HUMANS OR ANIMALS OR PLANTS OR PARTS THEREOF; BIOCIDES, e.g. AS DISINFECTANTS, AS PESTICIDES OR AS HERBICIDES; PEST REPELLANTS OR ATTRACTANTS; PLANT GROWTH REGULATORS
    • A01N25/00—Biocides, pest repellants or attractants, or plant growth regulators, characterised by their forms, or by their non-active ingredients or by their methods of application, e.g. seed treatment or sequential application; Substances for reducing the noxious effect of the active ingredients to organisms other than pests
    • A01N25/16—Foams
    • A—HUMAN NECESSITIES
    • A01—AGRICULTURE; FORESTRY; ANIMAL HUSBANDRY; HUNTING; TRAPPING; FISHING
    • A01N—PRESERVATION OF BODIES OF HUMANS OR ANIMALS OR PLANTS OR PARTS THEREOF; BIOCIDES, e.g. AS DISINFECTANTS, AS PESTICIDES OR AS HERBICIDES; PEST REPELLANTS OR ATTRACTANTS; PLANT GROWTH REGULATORS
    • A01N25/00—Biocides, pest repellants or attractants, or plant growth regulators, characterised by their forms, or by their non-active ingredients or by their methods of application, e.g. seed treatment or sequential application; Substances for reducing the noxious effect of the active ingredients to organisms other than pests
    • A01N25/30—Biocides, pest repellants or attractants, or plant growth regulators, characterised by their forms, or by their non-active ingredients or by their methods of application, e.g. seed treatment or sequential application; Substances for reducing the noxious effect of the active ingredients to organisms other than pests characterised by the surfactants
    • A—HUMAN NECESSITIES
    • A01—AGRICULTURE; FORESTRY; ANIMAL HUSBANDRY; HUNTING; TRAPPING; FISHING
    • A01N—PRESERVATION OF BODIES OF HUMANS OR ANIMALS OR PLANTS OR PARTS THEREOF; BIOCIDES, e.g. AS DISINFECTANTS, AS PESTICIDES OR AS HERBICIDES; PEST REPELLANTS OR ATTRACTANTS; PLANT GROWTH REGULATORS
    • A01N25/00—Biocides, pest repellants or attractants, or plant growth regulators, characterised by their forms, or by their non-active ingredients or by their methods of application, e.g. seed treatment or sequential application; Substances for reducing the noxious effect of the active ingredients to organisms other than pests
    • A01N25/34—Shaped forms, e.g. sheets, not provided for in any other sub-group of this main group
    • A—HUMAN NECESSITIES
    • A01—AGRICULTURE; FORESTRY; ANIMAL HUSBANDRY; HUNTING; TRAPPING; FISHING
    • A01N—PRESERVATION OF BODIES OF HUMANS OR ANIMALS OR PLANTS OR PARTS THEREOF; BIOCIDES, e.g. AS DISINFECTANTS, AS PESTICIDES OR AS HERBICIDES; PEST REPELLANTS OR ATTRACTANTS; PLANT GROWTH REGULATORS
    • A01N55/00—Biocides, pest repellants or attractants, or plant growth regulators, containing organic compounds containing elements other than carbon, hydrogen, halogen, oxygen, nitrogen and sulfur
    • A01N55/02—Biocides, pest repellants or attractants, or plant growth regulators, containing organic compounds containing elements other than carbon, hydrogen, halogen, oxygen, nitrogen and sulfur containing metal atoms
    • A—HUMAN NECESSITIES
    • A01—AGRICULTURE; FORESTRY; ANIMAL HUSBANDRY; HUNTING; TRAPPING; FISHING
    • A01N—PRESERVATION OF BODIES OF HUMANS OR ANIMALS OR PLANTS OR PARTS THEREOF; BIOCIDES, e.g. AS DISINFECTANTS, AS PESTICIDES OR AS HERBICIDES; PEST REPELLANTS OR ATTRACTANTS; PLANT GROWTH REGULATORS
    • A01N59/00—Biocides, pest repellants or attractants, or plant growth regulators containing elements or inorganic compounds
    • A01N59/16—Heavy metals; Compounds thereof
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M11/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising
    • D06M11/77—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with silicon or compounds thereof
    • D06M11/79—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with silicon or compounds thereof with silicon dioxide, silicic acids or their salts
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M11/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising
    • D06M11/83—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with metals; with metal-generating compounds, e.g. metal carbonyls; Reduction of metal compounds on textiles
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M13/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment
    • D06M13/322—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment with compounds containing nitrogen
    • D06M13/46—Compounds containing quaternary nitrogen atoms
    • D06M13/47—Compounds containing quaternary nitrogen atoms derived from heterocyclic compounds
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • D06M15/21—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M15/263—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of unsaturated carboxylic acids; Salts or esters thereof
    • D06M15/277—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of unsaturated carboxylic acids; Salts or esters thereof containing fluorine
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • D06M15/21—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M15/285—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of unsaturated carboxylic acid amides or imides
    • D06M15/295—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of unsaturated carboxylic acid amides or imides containing fluorine
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • D06M15/21—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M15/327—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of unsaturated alcohols or esters thereof
    • D06M15/33—Esters containing fluorine
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • D06M15/21—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M15/327—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of unsaturated alcohols or esters thereof
    • D06M15/333—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of unsaturated alcohols or esters thereof of vinyl acetate; Polyvinylalcohol
    • D06M15/3335—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of unsaturated alcohols or esters thereof of vinyl acetate; Polyvinylalcohol fluorinated
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • D06M15/37—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M15/564—Polyureas, polyurethanes or other polymers having ureide or urethane links; Precondensation products forming them
    • D06M15/576—Polyureas, polyurethanes or other polymers having ureide or urethane links; Precondensation products forming them containing fluorine
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • D06M15/37—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M15/643—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds containing silicon in the main chain
    • D06M15/657—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds containing silicon in the main chain containing fluorine
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/70—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment combined with mechanical treatment
    • D06M15/71—Cooling; Steaming or heating, e.g. in fluidised beds; with molten metals
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M23/00—Treatment of fibres, threads, yarns, fabrics or fibrous goods made from such materials, characterised by the process
    • D06M23/04—Processes in which the treating agent is applied in the form of a foam
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/23907—Pile or nap type surface or component
    • Y10T428/23986—With coating, impregnation, or bond

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  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • General Health & Medical Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Environmental Sciences (AREA)
  • Dentistry (AREA)
  • Wood Science & Technology (AREA)
  • Zoology (AREA)
  • Pest Control & Pesticides (AREA)
  • Agronomy & Crop Science (AREA)
  • Plant Pathology (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Toxicology (AREA)
  • Inorganic Chemistry (AREA)
  • Biochemistry (AREA)
  • Microbiology (AREA)
  • General Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
  • Chemical Or Physical Treatment Of Fibers (AREA)
  • Agricultural Chemicals And Associated Chemicals (AREA)
  • Carpets (AREA)

Abstract

Methods and treatment compositions for imparting durable antimicrobial properties to carpet are provided The method includes applying a composition comprising a first antimicrobial compound and a fiuoropolymer to the carpet substrate The carpet substrate may be steamed thereafter The treatment composition may comprise a fluoropolymer, an antimicrobial compound selected from a group consisting of zinc pyrithione, a silver-containing antimicrobial compound and combinations thereof, and a foamer Carpet products treated with the treatment composition or treated in accordance with the methods are also provided

Description

WO 2010/080903 PCT/US2010/020362 METHOD AND TREATMENT CON!POSm1ON FOR IMPARTING DURABLE ANTIMICROBIAL PROPERTIES TO CARPET CROSS REFERENCE TO RELATED APPLICATIONS 5 This application claims priority under 35 U.S.C. § 119(e) to L.S. Provisional Patent Application Ser No. 61/143,108, filed on January 7, 2009, which is incorporated herein by reference in its entirety. STATEMENT REGARDING FEDERALLY SPONSORED 10 RESEARCH OR DEVELOPMENT Not applicable. BACKGROUND OF THE INVENTION This invention relates generally to the field of carpets, and more particularly to 15 carpets having antimicrobial properties. Various antimicrobial treatments are currently used in tie carpet industry to impart antimicrobial properties to the manufactured carpet. The most popular methods include topical applications and dry cure applications of antimicrobial compounds to the carpet substrate. However, conventional antimicrobial treatment methods used in the 20 industry have damaging effects on carpet performance attributes such flame resistance, soil resistance, and color fastness. For example, many antimicrobial compounds, when applied topically to a carpet substrate following a fluoropolymer treatment and prior to drying in a dryer, will increase the flammability of the carpet 25 BRIEF SUMMARY OF THE INVENTION In one aspect, a method of treating carpet substrate is provided. The method may include applying a composition comprising a first antimicrobial compound and a fluoropolymer to the carpet substrate. In another aspect, a method of treating a carpet substrate is provided that 30 comprises applying a first antimicrobial compound and a fluoropolymer to the carpet substrate, and thereafter steaming the carpet substrate.
WO 2010/080903 PCT/US2010/020362 2 in another aspect, a treatment composition is provided for imparting durable antimicrobial properties to a carpet The treatment composition may comprise a fluoropolymer; an antimicrobial compound selected from a group consisting of zinc pyrithione, a silver-containing antimicrobial compound and combinations thereof; and a 5 foamer, Carpet products treated with the treatment composition or treated in accordance with the methods are also provided. BRIEF DESCRIPTION OF THE DRAWINGS 10 FIG. I is a diagram, illustrating a method of imparting durable antimicrobial properties to a carpet in accordance with one or more embodiments of the present invention. DETAILED DESCRIPTION OF THE INVENTION 15 Methods have been developed to provide a carpet with durable antimicrobial properties using modern continuous application equipment without negating or diminishing other desirable performance characteristics of the carpet. The present method can impart antimicrobial properties to a variety of carpet materials comprising various ty pes of fibers including, but not limited to, nylon, polyester, wool, 20 polypropylene, PTT, silk, cotton, rayon, acetate, and combinations thereof It has been discovered that durable antimicrobial properties may be imparted to a carpet in a continuous, single-step treatment with a fluoropolymer without diminishing combined performance attributes. in one embodiment. one or more antimicrobial compoundS are applied via foam in an exhaust application step utilizing a foam 25 applicator such as a Ksters Fluicon foam applicator (Andritz Kusters GmbH-) immediately before feeding the carpet into a steamer, Once the carpet exits the steamer, it typically is washed and extracted prior to entrance into the dryer. One embodiment of the method is illustrated in FIG. L, The treatment process 10 may be readily integrated with a continuous manufacturing process which feeds a carpet 30 substrate through various in-line process equipment, such as is known in the art. In treatment process 1.0, the carpet substrate may be first fed through a treatment apparatus 12, then inimediately through a steamer 1.4, then through a washing apparatus 16 and a dryer 18. In the treatment apparatus 12, the carpet substrate may be subjected to foam WO 2010/080903 PCT/US2010/020362 3 treatment with a foam comprising one or more suitable antimicrobial compounds and a fluoropolyrmer Various antimicrobial compounds mar be used including, but not limited to, Ultrafresh" DM-50, commercially available from Thompson Research Associates (Canada). Alphasanhi" RC-5000, conmetrcially available from Milliken Chernical 5 (Spartanburg, SC), Zinc Omadine'" and Reputexhi 20, commercially available from Arch Chemical (Norw alk, CT). In one embodiment, the antimicrobial compound is zinc pyrithione and/or AlphaSar0 h, which is an antimicrobial compound available from Milliken Chemicals (Spartanburg, South Carolina). Alphasan is believed to be a zirconium phosphate-based ceramic ion-exchange resin containing silver 10 In a preferred embodiment, a treatment composition is applied to the carpet substrate. The treatment composition may be in the form of a foam and may comprise a fluoropolymer, a foamer, magnesium sulfate liquid, zinc pyri throne, and a zirconium phosphate-based ceramic ion-exchange resin containing silver. Various fluoropolymers may be used including, but not limited to, Centapel EFP-7, commercially available from 15 Centaur Technologies (Dalton, GAr), Unidyne TG 580. TG 58 1. TG 2211 and TG 2511, all of which are commercially available from Daikin America, Inc. (Orangeburg, N ); PM 1396, PM 1399, PM 1400 and PM 1451 all of which are commercially available from 3M Specialty Chemicals Division (St. Paul, Minny Capstone' " RCP and CapstoneTM TUC. both of which are conimercially available from DuPont (Wilmington, 20 Del), in some embodiments, an aqueous composition of the treatment composition contains 3M PM 1.399 which is commercially available from 3M Innovative Products (Minneapolis, Minnesota). The fluoropolymer may be provided in an amount of about 0.05 to about 20 % owg (on the weight of the goods), or about 0.4% owg. The magnesium sulfate liquid may be provided in an amount of about 0.1 to about 20 % owg, 25 or about 2.0 % owg. Various foaners may be used including, but not limited to. Centafoam YEP-10, which is available from Centaur Technologies. The foamer may comprise about 0, 1 to about 100 g/l of the treatment composition or about 4.0 g/ of the treatment composition. The treatment mar also comprise Centafresh, which is available from Centaur 30 Technologies, in an amount of about 7 g/sq.yd. of carpet substrate. The treatment composition may also comprise various pH adjusting additives such as System 404, which is available from Phoenix Chemical (Calhoun, Geortia). The pH of the treatment composition may be about 2.0 to about 12.0, or about 2.1.
WO 2010/080903 PCT/US2010/020362 4 The treatment composition may comprise various antimicrobial compositions including, but not limited to, zinc pyrithione and silver-containing antimicrobial compounds, The zinc pyrithi one may comprise about 1 to about 50,000 ppm of the treatment composition or about 500 ppm of the treatment composition. Various silver 5 containing antimicrobial compounds may be used including Alphasan, which is available from Milliken Chemicals (Spartanburg, South Carolina). The silver-containing antimicrobial compound may comprise about I to about 50.000 ppm of the treatment composition or about 200 ppm of the treatment composition. in one embodiment, after the carpet substrate is treated with the fluoropoiymer 10 and antimicrobial compound composition, the carpet substrate is immediately steamed in the steamer 14. The carpet substrate is then rinsed and extracted by the washing apparatus 16 and dried in the dryer 18. It has been observed that treating the carpet substrate with a fluoropolymer and an antimicrobial compound in a single stage results in unexpected synergistic effects and 15 improved performance properties. In particular, the treated carpet demonstrates durable antimicrobial properties, excellent stain repellency and color fastness without diminished flame resistance. EXAMPLES In each of the following examples tufted filament polyester carpet dyed with 20 disperse dyes were from Beaulieu of America (Chatsworth, Georgia) were used for the sample carpet substrates. The following chemicals were also used in the examples: Zinc Pyrithione, an antimicrobial compound av ailable from Arch Chemicals (Norwalk, Connecticut); Alphasan, a silver containing antimicrobial compound available from Milliken 25 Chemicals (Spartanburg, South Carolina); Iivasan RCD, a sugar-derived freshener available fiom Huntsman Textile Effects (Switzerland) Centafresh, available from Centaur Technologies: PM 1399, a fluoropolymer available from 3M inovative Products (Minneapolis, Minnesota); Centafoam YEP-1 0, a foamer available from Centaur Technologies; Centex Binder, a binding agent available from Centaur 30 Technologies; System 404, available from Phoenix Chemical (Calhoun, Georgia) and magnesium sulfate liquid.
WO 2010/080903 PCT/US2010/020362 EXAMPLE ONE A foam was prepared conitaning 3M PM 1399 at 0.4% owg (on the weight of the goods), magnesium sulfate liquid at 2-0 % owg, Centafoam YEP-10 at 4,0 g/1 Centafresh at 7 g/sq yd The pH of the foam wvas adjusted to 2.1 with System 404. The 5 foam solution was applied to a polyester 1iaent carpet at 100% wet pick up. The carpet was then subjected to steam for 60 seconds then rinsed and extracted prior to entrance into the dryer. EXAMPLE TWO A polyester filament carpet was treated in a two step application process. The 10 first step was an exhaust application at 100% wet pick up via foam The solution used in the first step contained 3M PM 1399 at 0.4% oxxga (on the weight of the goods), magnesmim sulfate liquid at 2.0 %o wg. Centafoam YEP-10 at 4.0 g/l, Centafresh at 7 g/sqyd. The pH of the foam was adjusted to 2 x with System 404. The foam solution was applied to the fiber and then the carpet was subjected to steam for 60 seconds then 15 rinsed and extracted. After extraction the carpet was treated with the second step. The second step was an 8% wet pick up topical foam application. The solution used in the second step contained Alphasan at 1000ppm with Centafoan YEP-1 0 at 4.0 g/l. The solution was applied to the fiber by topical foam and then the carpet was placed into an oven at 140 20 degrees C until dry. EXAMPLE THREE A polyester filament carpet was treated in a two step application process. The first step was an exhaust application at 100% wet pick up via foam. The solution used in the first step contained 3M PM 1399 at 0,4% owg (on the weight of the goods), 25 magnesium sulfAte liquid at 2.0 %owg. Centafoam YEP- 10 at 4.0 g/l, Centafresh at 7 g/:sq.yd. The pH of the foam was adjusted to 2.1 with System 404 The foam solution was applied to the fiber and subjected to steam for 60 seconds then rinsed and extracted, After extraction the carpet w\ as treated with the second step. The second step was an 8% wet pick up topical foam application. The solution used in the second step 30 contained Alphasan at 1 000ppm with 0.5% owN Centex Binder and Centafoam YEP- 10 WO 2010/080903 PCT/US2010/020362 6 at 4.0 g/l. The solution was applied to the fiber by topical foam and then the carpet was placed into an oven at 140 degrees C until dry EXAMPLE FOUR A polyester filament carpet was treated in a two step application process. Thle 5 first step was an exhaust application at 100% wet pick up via foam. The solution usedin the first step contained 3M PM 1 399 at 0.4% owg (on the weight of the goods), magnesium sulfate liquid at 2,0 % owg, Centafoam Y-EP-10 at 4.0 g/L Centafresh at 7 g/sqyd. The pH of the foam was adj usted to 2.A with System 404. The foam solution was applied to the fiber and then the carpet was subjected to steani for 60 seconds then 10 rinsed and extracted, After extraction the carpet was treated with the second step. The second step was an 8% wet pick up topical foam application. The solution used in the second step contained Zinc Pyrithione at 500ppm and Centafoam YEP-10 at 4.0 g/1 The solution wxas apple ied to the fiber by topical foam and the carpet was then placed into an oven at 15 140 degrees C until diy. EXAMPLE FIVE A polyester filament carpet Nas treated in a two step application process. The first step was an exhaust application at 100% wet pick up via foam The solution used in the first step contained 3M PM 1399 at 0 4% owg (on the weight of the goods), 20 magnesium sulfate liquid at 2.0 %owg, Centafoam YEP-10 at 4.0 g/,L Centafresh at 7 g/sq.yd. The pH of the foam was adj Listed to 2. 1 with Systern 404. The foam solution was applied to the fiber and the carpet was subjected to steam for 60 seconds then rinsed and extracted. After extraction the carpet was treated with the second step. The second step was 25 an 8%N wet pick up topical foam application. The solution used in the second step contained Zinc Py'rithione at 500ppn with 0.%og Centex Binder and Centafoam YEP-i0 at 4.0 g/.L The solution was applied to the fiber by topical foam and the carpet was then placed into an oven at 140 degrees C until dry.
WO 2010/080903 PCT/US2010/020362 7 EXAMPLE SIX A polyester flament carpet was treated in a two step application process. The first step was an exhaust appli cation at 100% wet pick up via foam, The solution used in the first step contained 3M PM 1399 at 0.4% owg (on the weight of the goods), 5 magnesium sulfate liquid at 2.0 % owg, Centafoam YEP-10 at 4.0 gil, Centafresh at 7 g/sqyd. The pH of the foam was adj usted to 2. 1 with Sy stem 404. The foam solution was applied to the fiber and the carpet was subjected to steam for 60 seconds then rinsed and extracted. After extraction the carpet was treated width the second step. The second step was 10 an 8% wet pick up topical foam application. The solution used in the second step contained invasan at 500 ppm and Ceniafoam YEP-10 at 4.0 g/l. The solution was applied to the fiber by topical foam and the carpet was then placed into an oven at. 140 degrees C until dry. EXAM,*PLE SEVEN 15 A polyester filament carpet was treated in a two step application process. The first step was an exhaust application at 100% wet pick up via foam, The solution used in the first step contained 3M PM 1399 at 0 4% owg (on the weight of the goods), magnesium sulfate liquid at 2.0 % owg, Centafoam YEP-10 at 4.0 g/h, Centafresh at 7 g/sq~yd. The pH of the foam was adjusted to 2.1 with System 404 The foam solution 20 was applied to the fiber and the carpet was subjected to steam for 60 seconds then rinsed and extracted. After extraction the carpet was treated with the second step. The second step was an 8% wet pick up topical foam application. The solution used in the second step contained Invasan at 500 ppm with 0. 5%owg Centex Binder and Centafoam YEP-10 at 25 4.0 g/". The solution was applied to the fiber by topical foam and the carpet was then placed into an oven at 140 degrees C until dry. EXAMPLE EIGHT A polyester fdiament carpet was treated in a two step application process, The first step was an exhaust application at 100% wet pick up via foam. The solution used in 30 the first step contained 3M PM 1399 at 0.4% owg (on the weight of the goods), magnesium sulfate liquid at 2.0 % owg, Centafoam YEP-10 at 4.0 g/L Centafresh at 7 WO 2010/080903 PCT/US2010/020362 8 g/ sq.yd. The pH of the foam was adjusted to 2.1 with System 404. The foam solution was applied to the fiber and the carpet was subjected to steam for 60 seconds then rinsed and extracted. After extraction the carpet was treated with the second step. The second step was 5 an 8% wet pick up topical foam application. The solution used in the second step contained Alphasan at 200 ppm, Zinc Pyrithione at 500 ppm and Centafoarm YEP-10 at 4.0 /I. The solution was applied to the fiber by topical foam and the carpet was then placed into an oven at 140 degrees C until dry. 10 EXAMPLE NINE A polyester filament carpet was treated in a two step application process. The first step was an exhaust application at 100% wet pick up via foam. The solution used in the first step contained 3M PM 1399 at 0.4%) owg (on the weight of the goods), magnesium sulfate liquid at 20 % owg, Centafoam YEP-10 at 4.0 g/I, Centafresh at 7 15 g/sq.yd The pH of the foam was adjusted to 2.1 with System 404. The foam solution was applied to the fiber and the carpet was subjected to steam for 60 seconds then rinsed and extracted. After extraction the carpet wxas treated with the second step. The second step was an 8% wet pick up topical foam application. The solution used in the second step 20 contained Alphasan at 200 ppin, Zinc Pyrithione at 500 ppm with 0. 5% ovg Centex Binder and Centafoam YEP-10 at 4.0 g/, The solution was applied to the fiber by topical foam and the carpet wxas then placed into an oven at 140 degrees C until dry. EXAMPLE TEN A foam was prepared containing 3M PM 1399 at 0.4% owg (on the weight of the 25 goods), magnesium sul fate Iiquid at 2.0 % owg, Centafoam YEP- 10 at 4.0 g/ Centafresh at 7 g/sqlyd., Alphasan at 200 ppm, Zinc Pyrithione at 500 ppm. The pH of the foam was adjusted to 2.1 with System 404. The team solution was applied to the carpet and the carpet was subjected to steam for 60 seconds then rinsed and extracted prior to being placed into the dryer- WO 2010/080903 PCT/US2010/020362 9 EXAMPLE ELEVEN A foam was prepared containing 3M PM 1399 at 0.4% owg (on the weight of the goods), magnesium sulfate liquid at 2-0 % owg, Centafoam YEP-i0 at 4,0 g/I Centafresh at 7 g/sq yd., In vasan at 1,000 ppm. The pH of the foam was adjusted to 2.1 5 with System 404. The foam solution vas not applied to the carpet due to coagulation and precipitation EXAMPLE TWELVE A polyester filament carpet sample was maintained non-treated for use as a control. 10 EXAMPLE THIRTEEN All lest samples of EXAMPLES 1-12 were subjected to American Association of Textile Chemists and Coloi-ists (AATCC) test method 138, undergoing 10 cycles wash/extractions. The samipes we re further subjected to AA TCC test method 1 23 a pill test for flammnabi lty, a repellency test, and a 40 hour light fastness test. 15 Tra # AAICC AATCC AATCC Pill Repellency 40 hrs 123 Part 123 Par 23Part III Test ight I Fastness Exaple #1 Fail Fail Fai Iass Pass Pass Example t2 Fail Fai Fail Pass Pass Pass Ex'amnple #5 Pass Pass Fai Fai Pass F-ail ExnaRpe #6 Fail Fai ail Pass Pass Pass Example #7 Fail Fail Fail Fail Pass Pass example #8 Fad a Fail FaPas Pass Pass Example 4 Pass Pass Fail Fail Pass Fail. Example #10 Pass Pass Pass Pass Pass Pass Lviple 0l hail Fai1 Fail Pasl Fail Pass Example #48 Na NA NA NA NAi Nas Psa TABLE ONE RESULTS As demonstrated in T ABLE ONE, a synergistic effect exists with co-exhaustion of Zinec Pvrithione, Aiphasan, Centafresh, PM 1399, and Cen tafoamn YEP-10. Superior 20 results were achieve ed wxith this unexpected disco er. Excellent antib-acterial/antifungal WO 2010/080903 PCT/US2010/020362 101 results, repellency, and light fastness were achieved without causing flammability failures. Many vacations exist for the conditions previously outlined in the examples. Those skilled in the art recognize the many v:ariations for equipment and conditions 5 involving exhaust and topical application of chemical treatments, Previously outlined descriptions are supplied as examples and are not meant to be exclusive.

Claims (20)

1. A method of treating a carpet substrate compnsing: applying a composition comprising a first antimicrobial compound and a fluoropolymer to the carpet substrate.
2. The method of claim , further comprising steaming the carpet substrate after the composition is applied to the carpet substrate.
3. The method of claim 1, wherein the first antimicrobial compound comprises zinc pyrithione.
4. The method of claim 3, wherein the composition further comprises a silver containing antimicrobial cornpound.
5. The method of claim 3, wherein the composition com prices about I to about 50,000 ppm zinc pyrithione.
6. The method of claim 1, wherein the composition is applied to the carpet substrate in the form of a foam.
7- The method of claim 1, wherein the fluoropolymer is applied to the carpet substrate in an amount of about 0.05 to about 20 % owg.
8. A method of treating a carpet substrate comprising: applying a first antimicrobial compound and a fluoropolym.er to the carpet substrate; and thereafter steaming the carpet substrate.
9. The method of claim 8, wherein the first antimicrobial compound comprises zinc pyrithi one. WO 2010/080903 PCT/US2010/020362 12
10. The method of claim 9, further comprising applying a silver- containing antimicrobial compound to the carpet substrate.
11. The method of claim 8, wherein the first antimicrobial compound and the fluoropolymer are applied to the carpet substrate in the form of a. foam.
12. The method of claim 8, wherein the fluoropolymer is applied to the carpet substrate in an amount of about 0.05 to about 20 % owg.
13. The method of claim 9, wherein the first antimicrobial compound and the fluoropolvmer are applied to the carpet substrate as a treatment composition, the treatment composition comprising about I to about 50,000 ppm zinc pyrithione.
14. A treatment composition for imparting durable antimicrobial properties to a carpet compri sing: a fluoropolymer; an anti microbial compound selected from a group consisting of zinc pyrithione, a silver-containing antimicrobial compound and combinations thereof. and a foamer.
15. The treatment composition of claim 14, wherein the treatment composition comprises about 1 to about 50,000 ppm zinc pyrithione.
16. The treatment composition of claim 15, wherein the treatment composition comprises about I to about 50,000 ppm of the silver-containing antimicrobial compound.
17. The treatment composition of claim 14, wherein the treatment composition has a pH of about 2.0 to about 12. WO 2010/080903 PCT/US2010/020362 13
18. A carpet product treated in accordance with the method of claim 1.
19. A carpet product treated in accordance with the method of claim 8.
20. A carpet product treated with the treatment composition of claim 14.
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